Preventing Equipment Failures

The Hartford Steam Boiler Inspection and Insurance CompanyThe Hartford Steam Boiler Inspection and Insurance Company

Preventing Equipment

Failures

BoilersElectrical Distribution Systems

Air Conditioning Equipment

The Hartford Steam Boiler Inspection and Insurance Company

Any Questions?

Then let’s get started!


Preventing Equipment Failures


Boiler Maintenance


What is a boiler?

A closed vessel in which water is heated, steam is generated, or steam is superheated for use external to itself by the application of heat.


Boiler Categories

Power BoilerHigh Temperature Hot

Water BoilerHeating Boiler


Watertube BoilersComponents: Steam drum Water (mud)

drum Tubes


Watertube Boilers


Firetube Boilers


Firetube Boilers

Components: Shell (Drum) Tube Sheets,

Front & Rear Tubes (Flues) Furnace Stays (Stay

Bolts)


Firetube Scotch Marine


What could possibly go wrong with my

boiler?

Let’s take a look at some typical boiler

failures!


Major Causes of Boiler Failures

Low WaterPoor MaintenanceFailure of Controls and

Safety Devices


Low Water

Results in over temperature condition

Can cause extensive damage to boiler

Or

Catastrophic failure of the boiler





Poor Maintenance





Failure of Controls and Safety Devices









Preventing Boiler Failures

Proper OperationProper Maintenance It’s all up to you!


Boiler Operation

Prepare the boiler for operation

Starting the boilerRegular operationControls and safety valvesFeedwater treatment


Boiler Logs

Why use themWhat to includeHow to use them


Boiler Codes

ASME Boiler & Pressure Vessel Code

ASME Controls and Safety Devices

National Board Inspection Code

Jurisdictional Rules


Jurisdictional Rules

Inspection Frequencies Inspection types Installation requirementsRules for repair


HousekeepingSafetyFire PreventionCombustibles

•paint, oil, gas and cleaning productsFlammables

•wood, paper and cardboard •keep at least 8 to 10 feet from the

boilerEmergency Access


Controls & Safety Devices

Maintain control over boiler operation

Monitor operating conditionsProtect boiler from failure


Controls and Safety Devices

Controls and safety devices are installed on boilers to monitor, indicate, regulate, or control:

• Pressure• Temperature• Water Level• Combustion• Auxiliary Equipment


Pressure GagesVisual display of

operating pressures.Most accurate in

their mid-range.Dial range:

•Power Boilers: 1.5 – 2 times lowest safety valve setting


Control Water Seals Most controls are

designed to be subjected to water pressure.

A “loop” or trap is installed to protect controls from direct contact with steam.

Condensate fills the lines during normal operation.


Siphon Loops


Safety Valve Body Seat Disc Stem Spring Blow-Down Ring Huddling

Chamber


Low Water Fuel Cutoffs








Conclusion

Follow proper operating procedures

Regular maintenanceBe preparedAbove all …Work Safely!


Electrical Maintenance


Electrical Distribution System

Common Electrical Failures

“Figure illustrates specific causes of electrical failures and the individual contribution of each cause. This list is based upon twenty years of HSB claims data.”


Preventing Electrical Failures

CleanCool

DryTight

Yes

No

Yes

No

Did you observe any combustible material in the electrical room?

Yes

No

Changes to electrical system

Such as loads added or relocated or equipment upgraded or replaced.

Yes

No

Changes to electrical system

Such as loads added or relocated or equipment upgraded or replaced.

Have there been any changes to the electrical system in the last three (3) years?












Everything “Looks Okay”


…However!


Infrared Thermographic

Imaging Detects Hot

Spots Dirty, Loose,

Oxidized, or Corroded Connections.

Finds Phase Imbalance Problems.

Finds Undersized Wiring Problems.


Surge ProtectionSurge Protection Device (SPD)Transient Voltage Surge

Suppressor (TVSS)Diverts surge currents to

groundLimits the voltage across the

terminals of the equipment being protected


SPD - Zones of Protection

Zone 1: Service Entrance EquipmentIntercept surges before they enter the building

Zone 2: Distribution PanelSecond line of defense for each panel supplying critical or sensitive electronic equipment Protects against internally generated surges

Zone 3: Locally at Each Piece of EquipmentThird line of defenseProtects against internally generated surges

Grounding System is key to protection


Above all else…..

SAFETY FIRST!


Have a Safe Trip Home!

Documents

Preventing Equipment Failures